Miller Water Cooled Oil Free Centrifugal Chiller Installation Opration Maintenance Manual PDF

Miller Water-Cooled Oil-Free Centrifugal Chiller
Installation, Operation, Maintenance Manual
125-1800 Tons
440-6330 kW
50 & 60Hz
HFC-134a
Miller Air Conditioner Electric Co., Ltd

TABLE OF CONTENTS
INTRODUCTION
1. GENERAL DESCRIPTION.............................................................................................................................. 1
2. CHILLER NOMENCLATURE.......................................................................................................................... 1
3. SYSTEM WORKING PRINCIPLE................................................................................................................... 2
4. CHILLER COMPONENTS .............................................................................................................................. 4
4.1. E.G. SINGLE-COMP. CHILLER

4.2. E.G. DOUBLE-COMP. CHILLER
5. EQUIPMENT OVERVIEW ............................................................................................................................... 6
SHIPMENT AND INSTALLATION MANUAL
6. SHIPMENT .................................................................................................................................................... 14
7. BEFORE INSTALLATION............................................................................................................................. 15
7.1. RECEIVING
7.2. HOISTING
7.3. INSTALLATION REQUIREMENTS
7.3.1. FOUNDATION
7.3.2. ENVIRONMENT
7.3.3. CLEARANCE
8. WATER CIRCUITS INSTALLATION ............................................................................................................. 26
8.1. CHILLED AND COOLING WATER CIRCUIT

8.2. WATER PIPING CONNECTION
8.3. INSTALLATION OF FLOW SWITCH HOSE
8.4. WATER INJECTION
8.5. INSTALLATION PRECAUTION
9. ELECTRICAL INSTALLATION ..................................................................................................................... 30
9.1. GENERAL
9.2. ELECTRICAL CONTROL CABINET
9.2.1. INTRODUCTION OF CONTROL CABINET
9.2.2. TOUCH SCREEN
9.2.3. WIRING PRINCIPLE DIAGRAM
9.3. INTRODUCTION OF STARTER CABINET
9.3.1. CABLES ENTER FROM BELOW
9.3.2. CABLES ENTER FROM THE TOP
9.4. ACTIVE FILTER CABINET (USER SELECTABLE)
9.5. COMPONENTS TO BE PROVIDED BY THE CUSTOMER
9.6. ON-SITE WIRING
OPERATION MANUAL
10. OPERATION REQUIREMENT.................................................................................................................... 46
10.1. WATER QUALITY STANDARD

10.2. VARIABLE WATER FLOW
10.3. OPERATING RANGE
11. SYSTEM CHECKS BEFORE STARTING UP............................................................................................. 48
11.1. CHILLER CHECKS

11.2. WATER CIRCUIT CHECKS
11.3. SAFETY VALVE INSPECTION
11.4. ELECTRICAL CHECKS
12. PRESTART SYSTEM CHECKLIST ............................................................................................................ 51
13. STARTING UP............................................................................................................................................. 52
13.1. STARTING UP INSTRUCTIONS

13.2. INTERFACE INTRODUCTION
13.3. SHUTDOWN INSTRUCTIONS
14. DEBUG REPORT........................................................................................................................................ 62
MAINTENANCE
15. REGULAR MAINTENANCE ....................................................................................................................... 66
15.1. MAINTENANCE SCHEDULE
16. OPRATION MAINTENANCE GUIDANCE .................................................................................................. 68
16.1. OPERATION AND MAINTENANCE

16.1.1 INSPECTION OF OPERATION STATUS
16.1.2 MAINTENANCE
16.2. COMPRESSOR MAINTENANCE
16.3. ELECTRICAL MAINTENANCE
17. TROUBLESHOOTING ................................................................................................................................ 74

INTRODUCTION
1. GENERAL DESCRIPTION
Miller water-cooled oil-free centrifugal chiller is a comprehensive product developed by Miller. This
product series uses compressors, system parts and electrical components of well-known brands and
they are characterized by compact structure, cutting-edge technology, reliable control, cost-effective
operation and convenient installation. The computer-controlled system cannot only improve control
precision and reliability, but also provides infinitely variable speed energy adjustment, through which
the balance of chiller capacity and system load is optimized to effect economical operation, and is
controlled by means of large information display. Unattended and energy-saving operation can be
realized using the preset operation mode and operation program. The computer-controlled system
can be connected to a master computer so as to render network-based automatic management of
the whole building. This product can hence serve as a central air-condition system for hotels, stores
and office buildings.
2. CHILLER NOMENCLATURE
C C 0440 P W N I
Chiller system
Design number
Centrifugal chiller I Conventional model
J Large temperature
Capacity
difference model
Product type
Cooling only (R134a) Suitable voltage
B: 400V, 50Hz
Unit character
L: 380V, 60Hz
A=Air cooled
N: 380V, 50Hz
W=Water cooled
K: 460V, 60Hz
3. SYSTEM WORKING PRINCIPLE

The compressor takes in low-pressure superheated refrigerant gas from the evaporator and
compresses it into high-pressure, high-temperature steam-gas. The steam-gas discharges heat to
the cooling water when going through the condenser and is condensed into saturated or super-cool
refrigerating liquid, which flow is super-cooled by economizer and then regulated and pressure
reduced through expansion valve. Then, the liquid flows into the evaporator, where it absorbs heat
from chilled water, gasifies and is again taken in by the compressor to start a new cycle. Thus, the
water passing the evaporator is cooled down and flows into the air- conditioning area fan coil
chillers. Load balancing valve (hot gas bypass) is primarily used in low load conditions of single
comp. chiller to keep the compressor Online instead of cycling off.
Compressor
Evaporator
Load balancing valve
Condenser
Dry filter
Economizer
(For reference only)
Fig. 1
Compressor Compressor
Evaporator Evaporator
Condenser Condenser
Dry filter Dry filter
Economizers
(For reference only)
LEGEND
COMPONENT DESCRIPTION COMPONENT DESCRIPTION
Solenoid Valve Differential Pressure Switch
Electronic Expansion Valve Butterfly Valve
Ball Valve One-way Valve
Angle Valve Temperature Sensor
Relief Valve Pressure Sensor
Liquid Level Sensor Filter
Fig. 2
4. CHILLER COMPONENTS
4.1. e.g. SINGLE-COMP. CHILLER
FRONT VIEW
1 2 3 6
REAR VIEW
10
7 8 9
5
11
12
13
14
12
20 19 18 17 16 15
Fig. 3
4.2. e.g. DOUBLE-COMP. CHILLER

FRONT VIEW
1 2 3 4 5 6
REAR VIEW
10
7 9 8
11
12
14
20 17 16 15
19 18
LEGEND

1 Oil Free Centrifugal Compressor 11 Spray Cooling Pipe
2 Economizer Blow Down Pipe 12 Sight Glass
3 Control Cabinet 13 Load Balancing Valve
4 Start Cabinet 14 Filter
5 Eva. Safety Valve 15 Liquid Level Meter
6 Water Box 16 Isolation Valve
7 Suction Butterfly Valve 17 Dry Filter
8 Suction Pipe 18 EXV for System
9 Discharge Single-way Valve 19 EXV for Economizer
10 Discharge Pipe 20 Economizer
Fig. 4
5. EQUIPMENT OVERVIEW
Miller Centrifugal Liquid Chillers including the evaporator, condenser, oil-free compressor (including
VFD), control center, and all the interconnecting chiller piping and wiring.
The initial charge of refrigerant is supplied for each chiller. Actual shipping procedures for the chiller
will depend on the project-specific details.
COMPRESSOR
Miller Water-Cooled Oil-Free Centrifugal Chiller adopts oil free compressor, which includes magnetic
bearings, double-stage centrifugal compression, a variable speed permanent magnet motor and
intelligent electronic controls combine to create a sustainable energy efficient solution that is
compact, lightweight and quiet. The compressor sucks the low temperature and low pressure
refrigerant gas from the evaporator through the suction port, and then sends the high temperature
and high pressure refrigerant gas to the condenser through the discharge port. See figure 5.
Fig. 5 Fig. 6
Motor Cooling: Liquid refrigerant is channeled at full condenser pressure from the main liquid line to
the compressor to cool the electronic, mechanical, and electromechanical components (see Figure
6). The sub-cooled refrigerant enters the compressor through two solenoid valves and associated
fixed orifices located behind the service access cover. The orifices cause the refrigerant to expand,
thereby lowering its temperature.
VFD (Variable Frequency Drive) is integrated in the oil-free compressor. It includes an Insulated Gate
Bipolar Transistor (IGBT) type inverter that converts the DC voltage to an adjustable three-phase AC
voltage. Signals from the compressor controller determine the inverter output frequency, voltage and
phase, thereby regulating the motor speed.
The control curve is provided in the compressor control module for safe operation of the compressor
to make sure that the compressor always runs in safe regions by monitoring operation status of the
compressor in real time and timely adjusting the rotation speed after calculation and judgment.
FRONT VIEW REAR VIEW
1 2 3 4 5
10
11
9 6 8 7 6
LEGEND
COMPONENT DESCRIPTION FUNCTION

1 Top Access Cover Soft Start Board, IGBT and DC-DC are inside
2 Lift Anchor /
3 Suction Port /
4 Cable Harness Sensor Cable
5 Discharge Port /
6 Rear Support Base /
7 Capacitor Side Access Cover DC Capacitor Assembly is inside
8 Economizer Port /
9 Service Side Access Cover Backplane and BMCC are inside
Motor-cooling and Power
10 /
Electronics Cooling Access Port
11 Compressor I/O Board Cable /
Fig. 7
COMPRESSOR CONTROL AND MONITORING COMPONENTS:
Fig. 8
SCR: The AC line voltage is converted into a DC voltage by Silicon-Controlled Rectifiers (SCRs).DC capacitors
at the SCR output serve as energy storage and filter out the voltage ripple to provide a smooth DC voltage.
IGBT: The Insulated Gate Bipolar Transistor (IGBT) is an inverter that converts the DC voltage into an
adjustable three-phase AC voltage. Pulse Width Modulation (PWM) signals from the Bearing Motor
compressor Controller (BMCC) control the inverter output frequency and voltage.
Soft-Start Board: The Soft-Start Board limits inrush current by progressively increasing the conduction angle
of the SCRs. This technique is used at compressor start-up while the DC capacitors are charging up. The
soft-start function and the variable-speed drive combined limit the inrush current at startup.
BMCC: The hardware and software for the compressor controller and the bearing/motor controller physically
reside in the BMCC. The BMCC is the central processor of the compressor.
The Bearing PWM Amplifier: The Bearing PWM Amplifier supplies current to the radial and axial magnetic
bearing actuators.
Serial Driver: The Serial Driver module performs serial-to-parallel conversion on the stepper motor drive
signals from the BMCC.
Backplane: The Backplane physically interconnects the on-board plug-in modules with the power electronics,
IGV stepper motor, motor-cooling solenoids, rotor position sensors, and pressure/temperature sensors.
High-Voltage DC-DC Converter: DC-DC converters supply and electrically isolate the high and low DC
voltages that are required by the control circuits.
EVAPORATOR
Evaporator is a shell and tube, flooded type heat exchanger. Shell is fabricated from rolled carbon
steel plate with fusion welded seams; has carbon steel tube sheets, drilled and reamed to
accommodate the tubes, and intermediate tube supports spaced no more than four feet apart.
Tubes are high-efficiency, internally and externally enhanced type having plain copper lands at all
intermediate tube supports to provide maximum tube wall thickness at the support area. Each tube
has been roller expanded into the tube sheets providing a leak proof seal, and individually
replaceable. A liquid level sight glass is located on the side of the shell to aid in determining proper
refrigerant charge. A suction baffle eliminator is located above the tube bundle to prevent liquid
refrigerant carryover to the compressor.
Water boxes are removable to permit tube cleaning and replacement. Water boxes are designed for
10.0 bar design working pressure. Vent and drain connections with plugs will be provided on each
water box. See figure 9.
5 6 7 8 4
4
9
10
3
15 14 13 12 11
11 9
LEGEND

1 Differential Pressure Flow Switch Detection of water pressure difference
2 Standard Victaulic Type Groove Water pipe connection
3 Temperature Sensor Detection of water temperature
4 Release Valve Discharge air in the vessel
5 Needle Valve /
6 Relief Valve Pressure relief
7 Refrigerant Gas Outlet /
8 Lifting Holes Install hoisting locks
9 Tube-sheet of Evaporator /
10 Sight Glass Observe liquid level
11 Drain Valve Drainage during shutdown
12 Low Pressure Side of Load /
Balancing Pipeline
13 Refrigerant Filling Port /
14 Refrigerant Liquid Inlet /
15 Nameplate Bracket /
Fig. 9
CONDENSER
Condenser is of the shell and tube type. Shell is fabricated from rolled carbon steel plate with fusion
welded seams; has carbon steel tube sheets, drilled and reamed to accommodate the tubes; and
intermediate tube supports spaced no more than four feet apart.
Tubes are high-efficiency, internally and externally enhanced type having plain copper lands at all
intermediate tube supports to provide maximum tube wall thickness at the support area. Each tube
has been roller expanded into the tube sheets providing a leak proof seal, and individually
replaceable.
Water boxes are removable to permit tube cleaning and replacement. Water boxes are designed for
10.0 bar design working pressure. Vent and drain connections with plugs will be provided on each
water box. See figure 10.
4 5 6 7
3
8
2
9
10
18
15 13
11
14 12
17 16
LEGEND

1 Differential Pressure Flow Switch Detection of water pressure difference
2 Release Valve Discharge air in the vessel
3 Lifting Lug of Water Box Hoisting disassembled water box
4 Relief Valve Pressure relief
5 Economizer Bracket Fixed economizer
6 Low Pressure Side of /
Load Balancing Pipeline

7 Refrigerant Gas Inlet /
8 Lifting holes Install hoisting locks
9 Tubesheet of Condenser /
10 Sight Glass Observe liquid level
11 Base Foot /
12 Capacitive Type Liquid Level Transducer Measuring liquid level
13 Liquid Bag Storage refrigerant
14 Refrigerant Filling Port /
15 Refrigerant Liquid Outlet /
16 Nameplate Bracket /
17 Drain Valve Drainage during shutdown
18 Temperature sensor Detection of water temperature
Fig. 10
ECONOMIZER
Economizer is plate heat exchanger which could promote chiller energy efficiency.
Its operational principle is that the high-pressure liquid refrigerant from the condenser is divided into
two paths: A small part of the liquid flowing through the electronic expansion valve flows into the
evaporation side of the economizer to cool the other part of the liquid on the supercooled side. The
evaporation side liquid absorbs heat and evaporates into gas, then flows into the compressor. The
temperature of the liquid on the supercooled side decreases further after heat release, and the
degree of supercooling increases further. Then it enters the evaporator after throttling through the
main circuit electronic expansion valve.
The sub-cooling degree of the chiller can be increased by more than 10°C through the economizer,
and the maximum energy efficiency can be increased by about 10% under nominal operating
conditions.
EXV for System
Economizer
EXV for Economizer
Fig. 11
REFRIGERANT FLOW CONTROL
Control of refrigerant flow utilizes a single or multiple electronic expansion valve (EXV), to operate
within the full range from full load to the lowest loading capacity for the chiller. Condenser is provided
with a capacitive type liquid level transducer, which is wired to the chiller control system and is used
in electronic expansion valve control algorithm.
REFRIGERANT ISOLATION VALVES
Isolation valves have been installed on the compressor suction/discharge line and refrigerant liquid
line before leaving the factory. These valves allow isolation and storage of the refrigerant charge in
the chiller condenser during servicing, eliminating the time it takes to recover refrigerant. These
valves are positive shutoff, assuring integrity of the storage system.
CAUTION
The ball valve at the corresponding position must be closed during maintenance.
WATER FLOW SWITCHES
Differential Pressure Water Flow Switches are factory mounted in the evaporator and condenser
water nozzles, and are factory wired to the control panel. They measure the pressure difference
between the incoming and outgoing water to determine whether the water flow is appropriate. See
Figure 6 and Figure 7 for the water flow switches mounting location.
For the single-head, double-head and four-head chillers, the heat exchanger inlet and outlet are on
the same side, so the differential pressure flow switch can be completely installed in the factory. The
inlet and outlet of the three-head chiller are on the opposite side, and the parallel inlet and outlet are
on the same side but not flush, which causes the differential pressure flow switch could not be
completely installed in the factory and requires installation personnel to install it on site.
RELIEF VALVE
Safety valves are equipped on the evaporator and condenser , which are normally closed when the
chiller is in normal operation. When the heatexchanger s pressure exceeds the limit value of the
safety valve, the safety valves open automatically to relieve pressure. A ball valve is installed under
the relief valve and it must be opened in normal operation. When overhauling the safety valve,
ensure that the ball valve is closed.
INSULATION COTTON
Insulating cotton is installed on all low temperature surfaces of thechiller to prevent condensation.
The heat preservation areas are: Evaporator, Suction pipeline, Economizer, Liquid level sensor,
Compressor, etc.
MILLER CONTROL SYSTEM
The electric control of Miller magnetic suspension chiller is completed by starting cabinet and control
cabinet. The starting cabinet supplies power to the chiller, and the control cabinet controls the
operation of the chiller through microprocessor.
CAUTION
Each starting cabinet needs independent power supply, and users need to prepare power
supply according to the number of startup cabinets.
The chiller is controlled by a standalone microprocessor based control center. The Miller Control
Center provides control of chiller operation and monitoring of chiller sensors, actuators, relays and
switches.
keys which are redefined based on the screen displayed at the same time. The screen details all
operations and parameters, using a graphical representation of the chiller and its major components.
The panel language and data unit are chosen according to the user's needs. Usually, panel verbiage
is available in English as standard, and data is displayed in Metric units. The panel will display
countdown timer message so that the operator knows when to start or stop functions. Every
programmable point has a pop-up screen with the allowable ranges, so that the chiller cannot be
programmed to operate outside its design limits.
INTELLIGENT CLOUD SERVICE SYSTEM
Miller magnetic bearing centrifugal chiller with built-in smart network communication module, just by
an Internet cable Internet the user can upload unit operation parameters, the fault information to the
client end and Miller smart cloud services system. Enjoy the 24-hour butler service provided by
Miller's smart cloud service system.
Long-distance detection: detect each parameters of unit operation on real time, and accumulate the
data and make it in diagram. Improve the work efficiency of checking and recording personnel in the
air-conditioner room, reduce the workload of the management personnel in the air-conditioner room,
to achieve the goal of simple air-conditioner room or unattended air-conditioner room.
Default warning: the system can monitor the unit operation conditions constantly, and send alarming
information to the cloud services system or mobile terminals with relevant authorities, notify the
administrative staff of the air-conditioner room to quickly check and maintain it. Avoid the failure of
the unit and reduce the failure rate of the unit.
CENTRALIZED CONTROL SYSTEM (User Selectable)
Miller Oil-free Centrifugal Chiller allows users to centrally monitor the unit through centralized
monitoring system or monitoring computer, which can realize remote start-off, unit parameter
monitoring, fault alarm and other functions, and achieve efficient management of the entire
air-conditioning system.
Miller Oil-free Centrifugal Chiller can be equipped with a variety of communication interfaces (such
as MODBUS RTU, BACNET, LON, etc.) to meet various building automation requirements.
Installation and configuration is convenient and fast, and it is easy to implement centralized control.
SHIPMENT AND
INSTALLATION MANUAL
6. SHIPMENT
The surface of Miller magnetic suspension centrifugal chiller is coated with a beige two-component
epoxy resin primer. Entire chiller is protected with industrial-grade, reinforced shrink wrap covering
Protective covering is furnished on the Control Center to avoid collision when transporting.
The chiller is equipped with wooden pedestal to reduce the impact of bump and vibration on the
chiller during transportation.And the wooden pedestal should be removed before installing the chiller.
Water nozzles are capped with fitted plastic enclosures to avoid contaminants entering the unit
before installation.
Exterior surfaces of the chiller are protected with one coat of beige, two-component epoxy resin
primer. The acrylic resin and polyurethane finish design color pigment.
Each chiller can be broken down into several form shipment configurations for ease of transportation.
The specific splitting methods refer to the splitting manual.
The unit shall meet the following requirements during transportation:
1. In transit, chiller must be fixed and connected with shipping container in the vehicle.
2. The binding rope shall avoid touching the external small parts or squeezing the copper pipe line,
so as not to cause component damage, pipe deformation or cold media leakage.
3. The chiller must be firmly fixed during transport vehicle or container to ensure that the chiller
can't move around in the transportation process.
4. Keep the speed stable during transportation (avoid sudden braking and acceleration, etc.) to
avoid collision damage between the chiller and the panel car due to inertia!
5. During transportation, try to take the road in good condition and avoid driving outside the road
(avoid contacting with trees or guardrails to avoid damaging the protective layer of the chiller).
6. The chiller shall be inspected regularly, when relative displacement of the chiller is found, further
inspection and maintenance shall be carried out immediately, if the problem is serious, the situation
must be fixed completed!
7. If you encounter severe weather, should immediately find a safe place, and wait for the weather
environment to improve before shipping!
8. The chiller under transportation shall not extrude or collide with the protrusions on the surface of
the product during transport in to vehicle.
WARNING
Illegal transport is strictly prohibited.
7. BEFORE INSTALLATION
7.1. RECEIVING
The chiller should be inspected immediately after receipt for possible damage.
1. Check whether the documentation of the chiller is complete;
2. Check the model, specifications and accessories of the chiller according to the above
documents.
3. Check whether the chiller has damaged parts and whether the spare parts are complete.
4. Check for refrigerant leakage.
5. If there is any damage or doubt, please contact Miller after-sale immediately.
6. After inspection, appropriate protective measures should be taken. Do not remove the package
before installation to avoid damage to the equipment.
7.2. HOISTING
Fig. 12
The insulation cotton should be removed from the lifting lug of tubesheet before hoisting the unit.
After riging and installation of the chiller is completed, the riging holes should be insulated with
insulation cotton to avoid condensation or rust in the exposed position. When hoisting, extrusion of
surface parts, electronic cabinets and copper pipes should be avoided, so as to avoid damage to
parts, pipe deformation or leakage of refrigerant.
CAUTION
The chiller should be hoisted horizontally. Avoid collision of the chiller when handling! Care
must be taken not to scratch the packaging protective film and insulation cotton of the chiller
when handling!
The chiller can be lifted by fastening the rigging hooks to the four corners of the chiller where the
lifting holes are located. See Figure 12. A spreader bar must be used between the rigging lines to
prevent damage to the control panels, piping and electrical panels. The spreader bar length should
be equal to, or no more 500 mm shorter than the distance between the lifting holes located at
opposite ends of the chiller. Specific dimensions are shown in figures 14 to 16.
The chiller will require a single spreader bar of this length capable of supporting 1.5 times the
shipping weight of the chiller. Separately, all cables and hooks by themselves must also be capable
of supporting 1.5 times the shipping weight of the chiller. The chiller weight refers to the weight table
in 7.4.1, but the actual parameter are based on the nameplate.
CAUTION
The lifting lug position is subject to the actual instructions of the chiller. It is strictly prohibited
to change position at will!
CAUTION
The personnel at riging at site must wear safety helmet. Riging work shall be under the
unified command of a special person. The riging site should have enough lighting!
WARNING
The total load weights of lifting products shall not exceed the rated load of lifting equipment
or hanger.
When hoisting the product, if there is no specific provision in the special technical conditions, the
when level horizontally.
WARNING
After the product is hoisted, it is prohibited to stand on or below the product, and pedestrians
are prohibited to pass from the bottom!
7.3. INSTALLATION REQUIREMENTS

WARNING
It is strictly prohibited to trample on the system pipes and components during construction or
chiller maintenance.
7.3.1. FOUNDATION
The chiller must be mounted on a level concrete or steel base and capable of supporting the
operating weight of the chiller, and the chiller level must be guaranteed within (6.35mm). The
level of the chiller shall be measured by a laser level meter or a level ruler greater than 600 mm, so
that the chiller can maintain its levelness in the whole width range.
As Miller chillers are virtually vibration free, vibration pad is not factory-furnished and could be
chosen by users if needed. And it is not necessary to bolt the chiller to the mounting slab or
framework, but should this be desirable, mounting holes are provided in the chiller support at the four
corners.
7.3.2. ENVIRONMENT
Miller chillers are intended only for installation in an indoor or weather protected area. Equipment
room temperature for operating and standby conditions is 0°C to 40°C. Water chillers shall not be
exposed to dust, dirt, corrosive gases and excessive humidity to ensure that electrical components
can operate properly.
WARNING
Chillers are not allowed to be installed outdoors.
7.3.3. CLEARANCE
The installation space should be reserved according to the size of the unit, and the appropriate
service clearance must be provide at both ends of the chiller for possible removal of evaporator
and/or condenser tubes for cleaning. A doorway or other properly located opening may be used.
Sufficient clearance to permit normal service and maintenance work should be provided all around
and above the chiller. Clearance at all sides, including the top, at least 1 m. See figure 13.
8. WATER CIRCUITS INSTALLATION
LEGEND
SUGGESTED SUGGESTED
S/N SYMBOL DESCRIPTION S/N SYMBOL DESCRIPTION
POSITION POSITION
The point
connecting to the
Connecting
1 chiller, the front 7 Tee joint Places as shown
hose
and back of the
water pump
1-1.5m above the
Water inlet and
2 Thermometer
outlet pipeline
8 Expansion tank highest point of
the system
On the outlet
Water inlet and pipeline of the
3 Pressure gauge 9 Check valve
outlet pipeline chilled and
cooling water
Positions as
Water inlet and
shown, to switch
4 Shut-off valve
off the pipeline for
10 Flow switch outlet pipeline of
the chiller
maintenance
On the inlet
Electronic pipeline of the
On the water inlet
5 Descaling chilled water, at 11 Water pump
pipeline
instrument the back of the
water pump
On the water inlet
pipeline, at the
6 Water filter 12 Cooling tower /
front of the water
pump
Fig. 18
8.1. CHILLED AND COOLING WATER CIRCUIT

To prohibit debris from entering the pump, a strainer should be installed at the water supply line, and
ahead of the pump. The strainer with 20 mesh filters field-installed in the chilled water inlet line is
important to protect the chiller from debris or objects which could block flow through individual heat
exchanger tubes.
Strainers should be located on the inlet side of the evaporator and condenser. There is a label on the
connecting pipe of the chiller,and user can judge the direction of the water in and out according to the
label indication.
CAUTION
All external water piping must be cleaned before being connected to the chiller.
CAUTION
To ensure the chiller performance and longevity, air must be purged from both evaporator
and condenser the entire water circuit.
8.2. WATER PIPING CONNECTION

All vessels come standard with groove-type nozzles for Victaulic couplings, or optional flange
connections. The installing contractor must provide matching mechanical connections of the size and
type required. The size of the external pipe must be appropriate, and the pipe shall be aligned with
the inlet and outlet of the chiller in order to avoid stress and deformation. The nozzle dimensions are
shown in figures 14 to 16.
The installation precautions are as follows:
1. Chilled water and cooling water pumps should be located to discharge through the chiller to
assure positive pressure and flow through the chiller.
2. In cases where the water pump noise can be objectionable, vibration isolation sections are
recommended at both the inlet and outlet of the pump.
3. Usually, the water boxes can be interchanged (end for end) so that the water connections can
be made at either end of the chiller, but it is necessary to contact MIller after-sale before replacement.
Because the head gasket is disposable, it is necessary to communicate the supply cycle and
installation of the gasket. In addition, the cable of the water temperature sensor is arranged in slot, so
it is necessary to ensure that the sensor cable can also be transferred to the other side before
changing.
4. Piping should be arranged for ease of disassembly at the chiller for tube cleaning. All water
piping should be thoroughly cleaned of all dirt and debris before final connections are made to the
chiller.
5. Water pressure gauge connection taps and gauges must be provided in the field piping at the
inlet and outlet connections of both vessels for measuring the water pressure drop. The pressure
drops and flow rates for the various evaporators and condensers are job specific and the original job
documentation can be consulted for this information. Refer to the nameplate on the vessel shell for
identification.
6. The standard chiller is designed for 10.0 bar working pressure in both the chilled water and
cooling water circuits.
7. Piping must be adequately supported and braced independently of the chiller to avoid the
imposition of weight and strain on chiller components.
8. Chilled water piping must be adequately insulated.
9. Neither the evaporator nor the condenser is self-draining. Both must be blown out to help avoid
damage from freezing temperatures. If the air conditioning chiller is used in an environment where
the temperature is below zero, anti-freeze solution should be added to the water system!
CAUTION
Adding ethylene glycol or propylene to prevent freezing will increase the pressure drop and
result in performance degradation. Addition of ethylene glycol or propylene must be
approved by Miller.
CAUTION
If the chiller is shut down for a long time in winter season, the water in the water system must
be drained-out!
8.3. INSTALLATION OF FLOW SWITCH HOSE

CAUTION
For the whole delivery unit, the flow switch hose has been installed in the factory. For the
split delivery unit, the flow switch hose needs to be installed on site!
After the chiller is installed, the flow switch hose should be connected according to the following
figure. The specific operation steps are as follows:
1. When installing the differential pressure flow switch, the black part should be directed towards
the outlet pipe;
2. Remove the cap on the differential pressure switch;
3. Connect the two ends of hose with differential pressure flow switch and water pipe, and fasten
with wrench;
4. Place the hose neatly after installation.
CAUTION
Don't hang heavy objects on hoses.
8.4. WATER INJECTION

The chiller is drained of water in the factory and shipped with open drain valves in each head of the
evaporator and condenser. Be sure to close the valves prior to filling the vessel with fluid.
Before water injection, the sealing of each connecting part should be checked, and after water
injection, the leakage of the connecting part should be checked. If water leakage occurs, the water
injection should be stopped and the leaking area should be tightened according to the situation.
After water injection, the air in the pipeline should be discharged through the release valve when the
pump is running.
8.5. INSTALLATION PRECAUTION

Make all connections prior to filling with water. Run a preliminary leak check before insulating the
pipes and filling with water. Miller recommends consulting authorities in order to be compliant with
local building codes and safety regulations.
Additional considerations, as follows, should be made when designing the piping system:
1. Water pressure should be maintained throughout the system. Install regulating valves or
comparable pressure maintenance devices.
2. The piping system should be designed with a minimum number of elevation and directional
changes in order to minimize system pressure drop.
3. Adequate valves should be supplied to permit draining of water from the evaporator and
condenser.
4. Install air valves at the system high points and drain valves at the system low points. Additionally,
shutoff valves should be installed for chiller servicing.
5. Protect water from freezing by insulating water piping. Ensure there is a vapor barrier on the
outside of the insulation, in order to protect from pipe condensation within the insulation.
9. ELECTRICAL INSTALLATION
9.1. GENERAL
The core control part of MIller Oil-Free Centrifugal Chiller is a PLC controller designed for HVAC.
The operation interface adopts 10 inch color touch screen, and low-voltage devices adopt
high-matching electrical devices. The whole control system has high automation and reliability.
Please read the electrical wiring diagram and the instructions supplied together with the chiller before
installation. And install all power supply circuits as per national electrical code. The installation
precautions are as follows:
1. First, check whether the power supply and the circuit breaker meet the requirements.
2. The power cable of the chiller is three-phase four-wire system, and the specifications of the
power cable should be selected strictly according to the maximum operating current (power) of the
chiller. If the power supply distance is long, the specifications of power cables should be properly
upgraded.
WARNING
Units are strictly prohibited to be used outdoors. Effective protection measures should be
taken to prevent water and debris from entering the unit when storing.
3. The terminal of power cable can't be used as the key point of the incoming cable. Before
electrification, it is necessary to ensure that the cabinet and trough are clean and free of debris, and
to ensure that the cable tray is firmly fixed
4. After the wiring is finished, the inlet and outlet holes should be sealed (with fireproof mud, etc.).
WARNING
It is strictly forbidden to cut wires and cables in the electronic control cabinet. No other
unrelated cables are allowed in the electronic control cabinet.
WARNING
In order to ensure the safety of operators, the chiller must be grounded reliably!
5. Make sure that the unit is connected correctly according to the circuit diagram before power-on.
Ensure that the terminals in the compressor and the electronic cabinet are tightened and the
terminals of the press are well insulated.
CAUTION
6. Short-circuit problems must be checked before power-on. Ensure reliable grounding and good
insulation of the unit.
WARNING
Installation and debugging of equipment must be operated by professionals, and anti-static
measures should be taken during operation. It is strictly forbidden to install, debug or refit
the chiller privately!
7. After power-on, check whether the touch screen has fault information. It can't start before the
fault is reset.
WARNING
When the unit fails, it must be eliminated and restarted. It is forbidden to start the unit
forcibly without eliminating the failures.
8. If it is not an emergency, the unit should not be shut down by cutting off the main power supply.
CAUTION
It should be avoided to install the unit near high-power power devices, frequency
converters, power transmitters and other places with obvious electromagnetic interference
environment.
CAUTION
The Company shall not be liable for any accidents caused by non-compliance with the
above guidance, non-standard operation or negligence of work.
9.2. ELECTRICAL CONTROL CABINET
9.2.1. INTRODUCTION OF CONTROL CABINET

Miller Oil-free Centrifugal Chiller adopts PLC programmable control cabinet, which is mainly
composed of monopole switch, PLC, switch mode power supply, relay and wiring terminal. The
control cabinet completes the automatic control of the unit through the built-in program in the PLC. At
the same time, the control cabinet also has the protection functions of overload, short circuit and
phase absence.
The control cabinet is equipped with human-machine interface touch screen, which can realize easy
operation. In addition, according to the actual needs of users, the control cabinet can realize data
transmission based on communication protocols such as Modbus or BACnet.
(1) The control cabinet of sigle-comp. chiller
10
7
11
6
12
5
4 13
3 14
2
ModBus
LEGEND

1 Connection Terminal 8 Cooling Fans
2 I/O Board 9 Isolator
3 Intermediate Relay 10 Buzzer Alarm
4 Fuse (6A) 11 Wave Filter

5 Monopole Switch 12 Exv Control Panel
6 Cpu (PLC) 13 Cloud Service Module
7 Switch Mode Power Supply 14 Emergency Stop Button
(2) The control cabinet of double-comp. chiller
7 10
6
10
5
4 11
3 14
2 14
Fig. 19
The internal wiring of the control cabinet has been completed in the factory, but the 220 V power
supply needs field wiring, and the wiring location is shown in Figure 19. For the customized chiller,
the wiring diagram should be based on the electrical schematic diagram attached to the unit.
There are only instructions for the control cabinet of single-comp. chillers and double-comp. chillers.
For multi-comp. chillers, please refer to the instructions attached to the chiller or consult Miller after
sale.
WARNING
It is forbidden to supply power to other equipment from SMPS.
WARNING
Electrical control cabinet needs heat dissipation, so shutters must not be blocked!
WARNING
It is forbidden to expose the control cabinet to dust, corrosive gas and high humidity in order
to avoid short circuit.
Miller oil-free chiller is automatically controlled according to the outlet temperature set by the user.
The configuration of electric cabinets of different chillers is different. Unlike multi-head units,
single-head chiller is equipped with load balancing valve, which is driven by an IB-G module.
9.2.2. TOUCH SCREEN

The operation information of the compressor can be viewed on the touch screen. Users can also
export the operation data through the USB interface at the bottom of the touch screen.
1 2 3 4 5
COMPONENT DESCRIPTION PUEROSE

1 Power Supply Provide 220V power supply
2 RS-232 Support RS-232 communication
3 RS-485 Support RS-485 communication
4 USB Host Supporting USB data transfer
5 Ethernet Interface Supporting ethernet connecting
Fig. 20
CAUTION
RS-232 and RS-485 communication operations must be performed by professionals.
WARNING
Users are prohibited from modifying programs privately to avoid serious malfunctions.
9.2.3. WIRING PRINCIPLE DIAGRAM
CAUTION
The wiring diagram will be upgraded and updated without further notice. Please refer to the
actual display screen of the touch screen and the wiring diagram attached to the chiller.
CAUTION
PLC uses 24V input power supply. Users can choose the communication module according
to the actual needs.
GRAPHICAL SYMBOL DESCRIPTION
RS485
WIRING DIAGRAM (Double-COMP. Chiller)
NOTES
1. The device in the dotted box is configured
by the customer.
2."O" is internal wiring, is external wiring
Fig. 21
CPU (PLC) WIRING DIAGRAM (Double-COMP. Chiller)
1# Compressor control
Fig. 22
I/O BOARD WIRING DIAGRAM (Double-COMP. Chiller without EXV Driver)
RS485
1# Main EXV
1# Eco. EXV
1# Condenser
liquid level
1# Eco. temp.
sensor
1# Eco.
pressure sensor
2# Main EXV
2# Eco. EXV
2# Condenser
liquid level
2# Eco. temp.
sensor
2# Eco.
pressure sensor
Fig. 23
I/O BOARD WIRING DIAGRAM (Single-COMP. Chiller with EXV Driver)
RS485
Main EXV
Eco. EXV
Condenser
liquid level
Eco. temp.
sensor
Eco. pressure
sensor
Fig. 24
COMMUNICATION MODULE (User Selectable)
T2 T1
REF A+
B- B-
A+ REF
POL902
T1
A+
B-
REF
POL904
T-IP
POL908
Fig. 25
NOTES
POL90* is selected according to customer needs, POL902 is MODBUS RTU protocol,
POL904 is BACNET MS/TP protocol, and POL908 is BACNET IP protocol.
THERMINAL BOARD WIRING DIAGRAM (Double-COMP. Chiller)
ModBus
Fig. 26
9.3. INTRODUCTION OF STARTER CABINET

The starting cabinet of Miller Oil-free Chiller assembles switchgear, protective devices and auxiliary
equipment according to the electrical wiring diagram. It mainly consists of circuit breaker, fuse, EMC
filter and other components. When the unit fails or runs abnormally, it can cut off the circuit or alarm
by means of protective apparatus.
There are two ways to connect external cables to start cabinet:
1. The power cable should be connected from the bottom of the starter cabinet, and the
corresponding compressor power cord enters the cabinet from the back of the starter cabinet, as
shown in Figure 27.
2. The power cable should be connected from the top of the starter cabinet, and the corresponding
compressor power cord enters the cabinet from the top of the starter cabinet, as shown in Figure 28.
CAUTION
Do not shut down the unit by cutting off the main power supply unless there is an emergency.
9.3.1. CABLES ENTER FROM BELOW

Only power cables need to be connected to starter cabinet on site:
1. Remove the four screws around the inlet hole and remove the baffle;
2. Connect the power cable with the connection post through the inlet hole.
CAUTION
Make sure the cable connection is firm and reliable!
8 9
10
11
7
12
6
13
5
1 14
LEGEND
1 Reactor 8 Circuit Breaker
2 Fireproof Mud 9 Compressor Cable Entry Hole
3 Cooling Fans 10 Power Cable
4 EMC Wave Filter 11 Fast Fuse
5 Surge Protector 12 Ground Wire
6 Fuse (2A) 13 Power Cable Terminal
7 Fuse (100A) 14 Power Cable Entry Hole
Fig. 27
9.3.2. CABLES ENTER FROM THE TOP

When connecting, remove the four screws around the inlet hole and remove the baffle, and then
connect the power cable with the connection post through the inlet hole.
16
15
17
LEGEND

15 Compressor Cable 17 Power Cable Entry Hole
16 Compressor Cable Entry Hole
Fig. 28
9.4. ACTIVE FILTER CABINET (User Selectable)

Active power filter, APF for short. With the full digital control technology of DSP, harmonics can be
dynamically suppressed, reactive power compensation and three-phase unbalance can be carried
out, and power quality can be improved comprehensively.
APF detects the load current in real time by external current sensor CT, and extracts the harmonic
component of the load current through internal DSP calculation. Then it sends the PWM signal to
IGBT inside the compressor, and controls the inverter to generate a current equal to the load
harmonic and opposite to the load harmonic to compensate the harmonic current in the power grid,
so as to realize the filtering function.
Active filter cabinet is not suitable for all chillers. It should be selected according to the actual
situation of users. If the equipment is needed, please refer to the installation instruction manual
provided by Miller for installation and debugging.
CAUTION
Due to the different installation environment, please read the installation instructions
provided by Miller carefully before installation and use. Installation, debugging and startup
must be operated by professional personnel. If the user operates by himself, professional
personnel are required to supervise on-site.
CAUTION
The working environment requires no corrosive gas, no conductive dust. If the ambient
temperature exceeds the range of -10°C to 40°C , APF will not work. If it is not installed
immediately, please do not unpack the package and place the unit in a dry and ventilated
room.
CAUTION
Faults caused by misuse of users (such as reverse connection of CT lines, reverse
connection of power lines or wrong parameter setting) can be found during debugging . If the
compensation effect is poor but no alarm is given, please contact our electrical engineer.
WARNING
Pay attention to the danger of high pressure. The discharge time of DC capacitor is 5
minutes. It needs to wait for 10 minutes before operation.
9.5. COMPONENTS TO BE PROVIDED BY THE CUSTOMER

Dedicated switch box for the chiller: The switch box shall be equipped with an automatic circuit
breaker. Please refer to the maximum running current value in the technical parameter table of the
chiller for the specific setting value.
Power cables (wires) from the switch box to the chiller and all control wires for field connection: The
current capacity of a power cable (wire) shall be higher than the maximum current of the operating
chiller. The effect of the work environment and power supply distance should be taken into
consideration. The control wires for connecting control components on site should be 0.5-1.5 mm2
sheathed copper cores.
CAUTION
Each starter cabinet needs a separate power line!
CURRENT VARIATIONS:
MAXIMUM CURRENT (A)

MODEL 380V/50Hz & 380V/60Hz 400V/50Hz 460V/60Hz
CC0440* 178 (178×1) 178 (178×1) 155 (155×1)
CC0530* 180 (180×1) 180 (180×1) 160 (160×1)
CC0740* 225 (225×1) 214 (214×1) 185 (185×1)
CC0880* 356 (178×2) 356 (178×2) 310 (155×2)
CC1100* 360 (180×2) 360 (180×2) 320 (160×2)
CC1330* 534 (178×3) 534 (178×3) 465 (155×3)
CC1400* 450 (225×2) 428 (214×2) 370 (185×2)
CC1580* 540 (180×3) 540 (180×3) 480 (160×3)
CC1760* 712 (178×4) 712 (178×4) 620 (155×4)
CC1930* 720 (180×4) 720 (180×4) 640 (160×4)
CC2110* 720 (180×4) 720 (180×4) 640 (160×4)
CC2640* 810 (180×2+225×2) 788 (180×2+214×2) 690 (160×2+185×2)
CC2810* 900 (225×4) 856 (214×4) 740 (185×4)
Table below lists the allowable variation in voltage supplied to the chiller. The chiller nameplate is
stamped with the chiller voltage, and frequency.
VOLTAGE VARIATIONS:
OPERATING VOLTAGE (V)

FREQUENCY RATED VOLTAGE
MIN. MAX.
380 342 418
60Hz / 50Hz
400 360 440
( 5%)
460 414 506
CABLE SELECTION:
SERIAL CABLE DIAMETER GROUNDING CONDUCTOR MAXIMUM OPERATING

NUMBER (mm²) DIAMETER (mm²) CURRENT (A)
1 70 35 175
2 95 50 220
3 120 70 255
4 150 70 295
5 185 95 345
6 240 120 420

7 300 150 490
8 400 240 575
9 500 300 729
Note:
1. The following figures are suitable for 125~800 tons chillers, and chillers with refrigeration
capacity greater than 900 tons need to be customized according to the project requirements.
2. The cable selection in the table is suitable for the use of BV or copper wire of the same
specification, and there are three or less wires in the distribution hose.
3. The wiring specifications of this watch are based on the operating environment of 40°C, and the
cable operating temperature is 90°C. When the long-term use of the ring temperature is higher than
40°C, it is necessary to increase the wiring size or use a cable with a higher insulation permit
temperature.
4. When the three-phase power supply voltage deviation exceeds the nominal voltage by ±10%,
the line voltage loss does not meet the requirements of the normal operation of the electrical
equipment and the starting terminal voltage, please calculate and adjust the applicable line
according to the national standard path.
5. Different cable types, environments, temperatures, and laying methods will affect the maximum
current carrying capacity of the cable. This table is only for reference during wiring design. The actual
wiring design is selected according to the specific conditions on site.
9.6. ON-SITE WIRING

Before installing the power cable of the chiller, check whether the power supply meets the
requirements of the chiller (e.g. 3~, 380V, 50Hz) and whether the power cable (wire) meets the
requirements. Then connect the power cable as per wiring diagrams.
It should be avoided to install the chiller in places close to high-power power devices, frequency
converters, power transmitting devices and other places with obvious electromagnetic interference
environment.
For the electrical control part of chiller, refer to the wiring diagram in the attachment provided
together with the chiller.
CAUTION
The company shall not be liable for any accident caused by failure to follow the above
instructions, improper operation or negligence of work.
OPERATION MANUAL
10. OPERATION REQUIREMENT

10.1. WATER QUALITY STANDARD
When using cooling water and chilled water in bad quality, it would make chiller work abnormally. And
it is easier to have more debris such as limescale and sand in heat exchanger, which will reduce
water flow and heat exchange efficiency. Therefore, the recycled water must be filtered and softened
with chemicals before supplied to the chiller. It is necessary to analyze its PH, conductivity, chlorine
ion, sulfuric ion, ferrous content, etc. The following is the water quality standard adopted.
WATER QUALITY
The practical and economical application of liquid chillers requires that the quality of the water supply
for the condenser and evaporator be analyzed by a water treatment specialist. Water quality may
cause corrosion, scaling, sedimentation or organic growth, and these will degrade chiller
performance and increase operating and maintenance costs. Normally, performance may be
maintained by corrective water treatment and periodic cleaning of tubes. Special care must be taken
when utilizing open system water that is usually not treated (such as lakes, rivers, and ponds). it is
necessary to provide a larger allowance for fouling, and special tube and water head material may be
required to reduce damage from corrosion.
CAUTION
Water treatment service must be used. Miller is not responsible for damage or faulty
operation from untreated or improperly treated water
Water quality in condenser should meet the following conditions:
ITEM DETAIL ITEM DETAIL

pH Value (25°C) 6.5-8.0 Chloride Ion (Cl-) (mg/L) <200
Conductivity(25 ) (us/cm) <800 Sulfate (SO42-) (mg/L) <200
Total Ferrous (Fe) (mg/L) <1.0 Total alkalinity (CaCO3) (mg/L) <100
Total Hardness (CaCO3,25 ) (mg/L) <200 Silicon dioxide (SiO2) <50
Water quality in evaporator should meet the following conditions:
ITEM DETAIL ITEM DETAIL

pH Value (25°C) 6.5-8.0 Chloride Ion (Cl-) (mg/L) <50
Conductivity (25°C) (us/cm) <250 Sulfate (SO42-) (mg/L) <50
Total Ferrous (Fe) (mg/L) <0.3 Total alkalinity (CaCO3) (mg/L) <50
Total Hardness (CaCO3,25 ) (mg/L) <50 Silicon dioxide (SiO2) <50
10.2. VARIABLE WATER FLOW

FLOW SWITCH
Flow switches for the chilled water system is necessary to ensure adequate water flow to the
evaporator and condenser before starting the chiller. They prevent the chiller from starting without
sufficient water flow through the vessels, and also serve to shut down the chiller in the event that
water flow is interrupted to guard against evaporator freeze-up or excessive discharge pressure.
MIller furnishes factory-installed flow switches, otherwise the flow switch is to be field installed by
users.
VARIABLE FLOW OPERATION REQUIREMENTS
Miller chillers are well suited to installation where the chilled water and cooling water flow rates are
changed in the chiller, relative to the instantaneous building load and outdoor conditions. When
applying MIller chillers to variable volume (variable speed) pumping applications, the designer must
make sure Miller design parameters are met as follows:
1. The change of water flow will affect the outlet temperature of chilled water. When the initial
temperature of chilled water is close to the target temperature, too fast change of water flow will
easily lead to frequent start-up and shutdown of compressor, so that water flow shall not be altered at
a rate greater than 10% per minute.
2. That the water flow rates shall not exceed the maximum and minimum flows detailed in the
chiller selection sheet.
3. Variable pumps can be used on the chilled water side to make the water system more
energy-saving.
CAUTION
The chilled water flow should not be less than 50% of the nameplate.
4. Variable flow in the condenser is not recommended, as it generally raises the energy
consumption of the system by keeping the condenser pressure high in the chiller. Additionally, the
rate of fouling in the condenser will increase at lower water velocities associated with variable flow,
raising system maintenance costs.
CAUTION
The cooling water flow should not be less than 70% of the nameplate.
5. A lower flow rate change is normally used for better system stability and set point control.
CAUTION
After 24 hours of commissioning, the filter on the inlet side of the pump must be cleaned.
10.3. OPERATING RANGE

ITEM DETAIL
Voltage Range ±10% within rated voltage
Phase Imbalance ±2% within rated voltage
Mains Frequency ±5% within rated frequency
Entering Cooling Water
18°C 35°C
Temperature
Range of refrigerating Actual Leaving Chilled
3°C 20°C
condition Water Temperature
Target Leaving Chilled
5°C 20°C
Water temperature
Chilled water 50%~130% within rated flow
Water Flow Range
Cooling water ±30% within rated flow
Below 1.0MPa, also applicable for non-standard
Water Pressure Range
chillers of 1.6MPa, 2.0MPa, etc.
Operating Ambient Temperature 0°C 40°C
Storage Temperature -15°C 50°C
11. System Checks before Starting Up

11.1. CHILLER CHECKS
Before powering up the Miller chiller, check for any signs of damage. If damage is discovered,
contact Miller immediately to report it.
Ensure that all refrigerant valves are open including suction, discharge, motor cooling and liquid line
valves.
WARNING
The ball valve which is under the safety valve must be kept fully open during the operation
and shutdown of the chiller. It can only be closed when the safety valve is used for
proofreading, otherwise it may cause serious casualties!
11.2. WATER CIRCUIT CHECKS

1. Check the connection of water pipeline to ensure the correct direction of water flow.
2. Check whether all drain valves and release valves are closed. The water flow through the heat
exchanger must meet the design requirements.
3. Check the operation of terminal equipment.
4. Check whether the running direction of the pump and cooling tower fan is correct and whether
the water system is normal.
5. Check the water source of the expansion tank. Open the release valve of the chilled water
pipeline to drain the air.
6. Check whether the chiller's high and low pressure, suction and discharge temperature are
normal
7. Trial operation needs carried out when the main circuit breaker is connected to check whether
the compressor is running normally.
8. Ensure the cleanliness of circulating water to avoid blocking the inner pipes of heat exchangers.
9. All manual valves of the chiller must be opened before starting. After the above work is
completed, the terminal equipment can be started when the water temperature reaches the set
value.
CAUTION
The water quality flowing through the heat exchanger must meet the design requirements
and avoid dirty blockage and corrosion.
11.3. SAFETY VALVE INSPECTION

According to the specifications, safety valves should be connected to the pipeline outdoors to ensure
that refrigerants are discharged outdoors during pressure relief, and valves and pipelines should be
regularly inspected and leak tested.
CAUTION
Refrigerant gases are strictly forbidden to be discharged into airtight rooms. Safety valves
should be connected outdoors in accordance with ANSI/ASHRAE15 or other applicable
standards.
11.4. ELECTRICAL CHECKS

The control cabinet has been tested before leaving the factory, but due to the influence of possible
harmful factors, please cooperate with the after-sales personnel to make careful inspection before
putting into operation.
1. Check whether the electrical system is consistent with the chiller and check whether the chiller
switch meets the maximum operating capacity requirement of the chiller. This machine uses
three-phase power supply, voltage unbalance rate should be less than 2%.
2. Check all mains electrical connections. Ensure that there is a neutral and an earth present and
both have been connected to the appropriate bus bar in the electrical cabinet as these are essential
for correct operation of the chiller. Tighten terminals if needed.
3. Please fixed screw for each electrical element in the cabinet before switching on the power.
CAUTION
The power supply line terminal of the starting cabinet cannot be used as the weight support
point of the inlet wire cable.
4. Before power on, it is necessary to check whether there is a short circuit problem, ensure that
the machine group is grounded reliably and well, and check whether there is condensing water or
other things in the locker.
CAUTION
Do not install, connect or direct other electrical equipment at the electrical or gas connection
point with the device in the electrical control cabinet.
5. Before power on, confirm that the wiring of the chiller has been correctly wired according to the
wiring diagram. The fixing screws of the electrical components in the electrical control cabinet are
fastened. The terminals in the terminal box of the compressor (compressor) are fastened, and the
insulation of each terminal of the press is good.
WARNING
Above checks must be performed with the power off. Removal of covers with power applied
will result in exposure to high voltages. Failure to have power off may result in electrocution.
12. PRESTART SYSTEM CHECKLIST

ITEM TASK YES NO N/A
Chiller system mounted on a level surface ( (6.35mm) )
Refrigerant pressure present and no signs of refrigerant leaks
Chiller has no signs of damage

General
All insulation in sound condition ( not damaged by rigging
equipment)
Adequate service clearance available, as per Miller
requirements
Power leads connected to the chiller power panel(s)
All interlock wiring complete to control panel and complies

with specifications
Electrical Pump starters and interlock wired
Cooling tower fans and controls wired
Condenser pump starting relay (CWR) installed and wired
Piping complete
Water system filled, vented
Chilled Water Pumps installed, (rotation checked), strainers cleaned
Strainer installed at evaporator inlet
Water system operated and flow balanced to meet chiller

design requirements
Cooling tower flushed, filled and vented
Pumps installed, (rotation checked), strainers cleaned

Cooling
Water Strainer installed at condenser inlet
(Condenser
Water) Controls (3-way, bypass valves, etc.) operable
Water system operated and flow balanced to meet chiller

requirements
13. STARTING UP
13.1. STARTING UP INSTRUCTIONS
1. Chiller can be linked with pumps and cooling tower fans, but in any case, it must ensure that the
chilled water pump and cooling water pump have been turned on before the compressor starts. If the
chiller receives the start-up instructions and detects that the water flow is too low or no flow, the unit
will alarm and will not start.
2. After the single pole switch is switched on, the control circuit starts to be energized and the PLC
and touch screen start to work. At this point, the touch screen displays the startup interface. If the
touch screen is not displayed, the power supply wiring of AC220V power supply and DC24V power
supply should be checked immediately.
WARNING
The unit shall be operated and managed by careerman. When abnormal conditions are
found, the unit shall be shut down in time to find out the causes and eliminate faults.
Operation with faults is strictly prohibited.
WARNING
It is strictly forbidden to operate when the door of the electronic control cabinet is opened.
CAUTION
After shutdown, it takes at least five minutes to turn on.
13.2. INTERFACE INTRODUCTION

CAUTION
The control interface will be upgraded and updated without further notice. Please refer to the
actual display screen of the touch screen of the unit.
User login
After the control cabinet with an operation panel is powered on and the single pole switch is closed,
at t
Touch screen after the completion of the completion of automatic jump to the user login screen
(Figure 29). In this screen, the version number of the touch screen and PLC program, the current
date, time and week of the system are displayed.
Click the numeric keypad, enter the correct user password, chick [ENTER] jump to the main screen.
If the wrong password is entered, please input the password again, input the password again (Figure
30), re-enter the correct password and click [ENTER] to enter the main screen.
Miller Oil-Free Centrifugal Chiller Miller Oil-Free Centrifugal Chiller
Fig. 29 Fig. 30
The main screen
In the main screen display chiller status, operating mode, target temperature, evaporator water
temperature, evaporator water temperature, condenser water temperature, condenser water
temperature, the load rate of each compressor.
Fig.31 Fig. 32
Standby, show the static chiller picture, click on the boot button, pop-up boot confirmation screen,
click [Start] chiller to start, click [Esc] to cancel the boot.
After the chiller is turned on, the dynamic picture of the chiller will be displayed. At this time, the [RUN]
button changes to the [STOP] button
Fig. 33 Fig. 34
Click [STOP] button, the pop-up shutdown confirmation screen, click [Confirm] chiller start shutdown,
click [Esc] to cancel shutdown.
The state view
Click [Status] to enter the chiller parameter screen. In this screen, the display water temperature set
value, the current water temperature, EXV opening, frozen pump state, chilled water inlet
temperature, chilled water temperature, cooling pump state, cooling water inlet temperature, cooling
water temperature. The water outlet temperature can be set on this screen.
Click [Page Down] to enter the Economizer Status. In this screen, the display temperature, pressure,
superheat, AEX opening.
Fig. 35.1 Fig. 35.2
Click [COMPRESSOR] button to enter the compressor parameter screen (Figure 36). In this screen,
the switch status, suction pressure, exhaust pressure (cylinder), exhaust pressure (compressor),
suction temperature, exhaust temperature, running time, desired speed, actual speed, Vibration
speed, compressor load, IGV opening, the desired power, the actual power, press current, press
voltage, EXV opening, level and other parameters. When the press run time of less than 1 hour, the
display of the number of minutes of operation; Press the machine running time after 1 hour, only
show the number of hours.
Fig. 36 Fig. 37
Curve view
Click the [Curve] button to display the real-time temperature profile shown in Figure 37.The curve
reflects the trend of the chilled water and cooling water temperature curves within 1 hour.
Temperature curve coordinates below the time scale. Different water temperatures are distinguished
by different colors. Click the color mark in front of the water temperature name to hide or display the
corresponding water temperature curve. For example: click the frozen water temperature in front
of the mark, you can hide the frozen water temperature curve, click again to restore the display.
Click the [History Curve] button to display the historical temperature curve shown in Fig. The curve
reflects the trend of chilled water and cooling water temperature change within 6 hours. Temperature
curve coordinates below the time scale. Different water temperatures are distinguished by different
colors. Click the color mark in front of the water temperature name to hide or display the
corresponding water temperature curve. For example: click the Cond water temperature in front
of the mark, you can hide the frozen water temperature curve, click again to restore the display.
Click the drop-down list to select the date you want to view.
Fig. 38 Fig. 39
Click the [Data Report] button to display the data report screen. In this screen you can view the
details of the freezing water temperature, the freezing water temperature, the cooling water
temperature, and the cooling water temperature. The default interval for saving data is 60s, which
can be modified. The daily data is stored in 1 file, click on the drop-down list to select the date you
want to view.
Fig. 40 Fig. 41
Click the [Data Backup] button to pop up the data backup to the USB disk to confirm the screen, click
[Confirm] button, you can store the data stored in the touch screen to export to the U disk, click [ESC]
button to cancel the export.
Click the [Data Delete] button to pop up the data clear confirmation screen. Click the [Confirm] button
to clear all the water temperature data stored in the touch screen. Click the [Esc] button to cancel.
Alarm records
Click the [Alarm Record] button to jump to the current fault screen.
When the chiller is faulty, it will display the alarm sign at the top of the interface. Clicking the alarm
flag will jump to the current fault information interface. When the fault is cleared and the "Reset"
button is pressed, the corresponding fault disappears from the fault window.
Fig. 42 Fig. 43
Click the [Alarm History] button to jump to the fault history screen. This interface is mainly used to
display chiller fault information, and store the information for later view. As shown, all faults have a
fault occurrence time, recovery time and fault information. If the fault is too much, a screen display is
not complete. You can use up and down flip signs or scroll bar to flip the screen. There are two colors
for the fault record: when the fault occurs, it is red; when the fault is restored, it is blue. Please note
these colors in order to correctly determine the fault.
Click the [Alarm] button to enter the troubleshooting screen. In this screen, some of the common
causes of the malfunction and the exclusion of the method described in accordance with these
instructions can rule out some common faults. Troubleshooting a total of four screens, click
[NEXTPAGE] and [LASTPAGE], you can switch these screens.
Fig. 44 Fig. 45
Fig. 46 Fig. 47
Timing settings
Click the [Schedule] button to enter the timing setting screen shown in Figure 48. In this screen, you
can set up three time periods. After the timer function is turned on, the chiller will start up or shut
down automatically at the set time. The timing functions of the three timers can be turned on or off
individually. Timing master switch is turned on, the timing will be effective, the timing of the main
switch is turned off, the three sections of time are invalid. The timing is valid only when the timing flag
is displayed at the top of the screen. The three time periods must be set in the order of time. The start
time of the time range is at least 00:00 and the end time of the time range is 23:59. According to user
needs can set the week of the implementation of the date, open the week to set the main switch to be
effective. Note: If the week setting master switch is not on, the default is valid every day.
Fig. 48 Fig. 49
Note: The timer function must be on or off in the chiller standby state. After the chiller is started, the
timer setting cannot be operated, as shown in Figure 49.
User parameter settings
Click the [USER SET] button to enter the user setting screen.
Fig. 50
The target temperature is the water outlet target temperature setting value of the chiller. Click the
value input box to pop up the numeric keypad and input the temperature to be set. Each time the
button is clicked, the target value is reduced by 0.1 °C. each time the button is clicked,
the target value is increased by 0.1 °C.
According to the need to select the number of press, said 1# compressor is not selected,
said the 1# compressor was selected.
Chiller control mode is divided into local and remote two, according to need to choose. Local refers to
the use of touch-screen control chiller, remote is through the remote switch or Modbus
communication control chiller.
Select the press and control mode, the chiller must be in standby conditions, the chiller cannot
operate when running. After the user selection is completed, the permanent storage is performed
and the set parameters are stored in the power-down retention data area of the PLC controller.
Permanent storage must also be done when the chiller is in standby mode. The Persistent Store
button will remain active for 3 seconds. The PLC controller restarts permanently.
Password Set
Click [PASSWORD SET] to enter the user password modification screen. Click the input box, pop-up
numeric keypad, enter the original password and the new password and click [CONFIRM] button to
modify the implementation. Password setting range: 0001 ~ 9999, the password cannot be set to 0.
Fig. 51 Fig. 52
When the original password is wrong, the system displays the message "old password incorrect".
If the new password is not entered twice, the message "New password inconsistency" is displayed,
as shown in Figure 53.
Fig. 53 Fig. 54
If the original password is correct and the new password is the same twice, the message "Password
has changed" is displayed.
Time Set
Click the [TIME CALIB] button to enter the clock calibration screen.
When the PLC time and the real time difference is large, the need for clock calibration. To change the
time of the touch screen to match the real time, click the [TIME SYNC] button, and the PLC time will
match the time of the touch screen.
Note: Press [TIME SYNC] for 2 seconds. When the chiller starts, the time synchronization is disabled
and the [TIME SYNC] button is disabled.
Fig. 55
HMI Set
Click the [HMI SET] button to enter the touch screen setup screen.
Language selection: can choose Chinese or English display, for the installation of the chiller in the
country, this feature is not open.
Screen saver time: The default setting is 5 minutes, if not touch screen within 5 minutes to enter the
screen saver screen. Screen saver time setting range is 0 ~ 60, in minutes, set to 0, the touch screen
has been lit, the screen saver function is canceled. Figure 29 shows the time when the screen saver
screen, hand click anywhere on this screen, enters the user login screen.
Backlight time: The default setting is 10 minutes. If the screen is not touched within 10 minutes, the
touch screen will be blank and no screen will be displayed. The main purpose of this function is to
save power and extend the life of the touch screen.
Backlight brightness: the user according to the surrounding environment, hand-click slider or slide
the slider to set the appropriate backlight brightness.
Key Sound: When [On] is selected, each button on the touch screen will give a "Droplet" prompt.
When [Off] is selected, no sound is displayed on the touch screen.
Miller Oil-Free Centrifugal Chiller
Fig. 56 Fig. 57
13.3. SHUTDOWN INSTRUCTIONS

1. Shutdown instructions
(1) The chiller can shut down automatically according to the temperature of chilled water outlet.
The chiller can shut down manually through the [STOP] button on the touch screen, but it can not
shut down by cutting off the main power supply.
(2) When shutting down, in any case, ensure that all compressors are closed before the pump can
be delayed closing (when the pump and the main engine are linked, the pump will automatically be
delayed shutting down according to the program).
(3) If the ambient temperature during shutdown is low, the pump should be turned on to ensure the
circulation of water in the system if there is a possibility of freezing and the water in the system
cannot be discharged.
WARNING
The circuit breaker in the electric control cabinet must not be disconnected at will, and it
cannot be used to shut down during normal operation. The circuit breaker that trips due to
overload can continue to be used. If it trips due to a short circuit, the circuit breaker must be
replaced.
2. Seasonal shutdown procedure:
(1) Refer to the general shutdown procedure for operation.
(2) In order to prevent serious damage caused by the freezing of the heat exchange tube and the
heat exchanger barrel, antifreeze measures should be taken during seasonal shutdown:
If the ambient temperature is above 0 °C during shutdown, the water in the system will not
freeze, but it is still recommended to drain the water inside the heat exchanger and blow it off with
high pressure air to avoid corrosion of the heat exchanger.
If the ambient temperature may be below 0 °C, the water in the evaporator and condenser must
be drained. To avoid corrosion, blow off the water with high pressure air and turn off the pump.
14. DEBUG REPORT

To ensure reliable operation in the long term, debugging of the chiller should be engaged by
technicians from Miller or by personnel with adequate knowledge on air-conditioning and water
system under the guidance of Miller technicians. Routine servicing and operation should also be
engaged by air-con technicians that have received adequate training.
SITE INFORMATION
____ __ Address: __ ____ __ __

Tel / Fax: ____ __ Chiller Type: ___ ___ Serial Number: ____ _
Debug Time: ____ _ Miller Debug Technician: ______
Installation Company: ___ ___
Installation Company Adjustor: _____ _
BEFORE STARTING UP
A. System Check
Item Yes No Notes

1. Damage, deformation, dislocation of chiller appearance and its component.
2. Refrigerant leak on each part of chiller.
3. On/Off status of all angle valve, ball valve, drain valve, butterfly valve in
normal condition
4. Bonnet on all service valve, angle valve, and needle valve.
5. Opening of ball valve of refrigerant system relief valve.
6. Thermally conductive silica gel inside blank tubing of entering/leaving water
temperature transducer.
7. Sticking label fall off chiller component.
8. Paint scaling or crack on the surface of heat exchanger, etc.
9. System water quality conforms to operating instruction.
10. Damage or looseness on the wiring of pressure, temperature, flow switch
liquid level detector, etc.
11. Rust on chiller component.
12. High temperature, high humidity, or air mixing with corrosives such as acid
in installation environment.
13. If needs to split the chiller. If yes, special care must be taken to electronic
control and powering up check.
B. Electronic Check
Item Yes No Notes

1. Damage, deformation, dislocation of control cabinet appearance and its
inner components.
2. Abrasion or looseness of components and wiring inside control cabinet.

3. 380V/400V/460V chiller cable is made of copper and meet instruction
demand.
4. Binding post of electric reactor is smooth, without paint and patina.
5. Falling or lax close of cabinet lock.
6. Control cabinet in/out fan rotation in normal condition.
7. Complete data of specification, wiring diagram, etc attached to chiller.
8. Water pump and cooling tower fan interact with main engine on site.
9. Integrated controlling system to monitor chiller on site.
10. Compressor number coincides with control system number in
multiple-compressor chiller.
11. High-power device which needs often start and stop on site, such as heavy
lift, welding machine, air compressor, frequency converter, etc.
operation of control system inner parts.
C. Powering Up Check
Item Yes No Notes

1. Parameters of compressor and water temperature are in normal range.
2. Power light of compressor I/O board turns green.
3. PLC communication light is in good condition.
4. Chiller power supply voltage and unbalance are within required using
scope.
D. Recording
1. Chilled water pump flux___ _m3/h, Lift____ m, Number____, Motor power____ kW, Notes:____
2. Cooling water pump flux____m3/h, Lift____ m, Number____, Motor power____ kW, Notes:____
3. Cooling tower rated volume____m3/h, Lift____ m, Number____, Cooling tower type/brand____,
Notes:____
4. Chilled water rated volume____m3/h, Cooling water rated volume____m3/h, Refrigerant type____,
Charge____ kg
5. Chiller rated voltage____ V, Input power____ kW, Rated frequency____ Hz, Target temperature
setting____ °C
START-UP RECORD
A. Record of Interface Display & BMCC Version Number
1. Interface display and operation coincide with Instruction Notes:__________

2. Interface display coincides with chiller operating state Notes:__________
3. BMCC version number:________ , Touch-screen program version Number:________
Chiller program version number:________
B. Test Data ( full-load test, at least recording 4 groups of data, time interval between each group of
data is more than 5 minutes )
Time Time Time

Record Item Unit
1# 2# 3# 4# 1# 2# 3# 4# 1# 2# 3# 4#
Evaporator entering
°C
water temperature
Evaporator leaving
°C
water temperature
Evaporator water 3
m /h
flow
Condenser entering
°C
water temperature
Condenser leaving
°C
water temperature
Condenser water 3
m /h
flow
Discharge pressure MPa
Discharge
°C
temperature
Suction pressure MPa
Suction temperature °C
Pressure ratio /
Liquid level %
Load %
Compressor actual
RPM
rotating speed
IGV opening %
Power supply A
A
phase current
Power supply B
A
phase current
Power supply C
A
phase current
Evaporator entering
MPa
water pressure
Evaporator leaving
MPa
water pressure
Condenser entering
MPa
water pressure
Condenser leaving MPa
water pressure
Power voltage A-B V
Power voltage B-C V
Power voltage C-A V

Compressor accu-
h
mulative runtime
Conclusion Opinion:
Miller adjustor signature Dealer signature User representative signature

MAINTENANCE
15. REGULAR MAINTENANCE

15.1. MAINTENANCE SCHEDULE
To provide smooth operation at peak capacity and to avoid damage to package components, Miller
has formulated the following regular maintenance procedures. Equipment maintenance should be
carried out by professional and technical personnel.
Frequency
Item Task
Monthly Quarterly Annually
Check main power supply voltages
Check electrical terminals are tight
Electrical
Check there are no hot spots / discoloration
Checks
on power cables
Check amperages are as per design
Check communication cables are secure
Check pressure and temperature sensor
connections are secure
Check discharge and suction pressure/
temperature sensors for accuracy against
calibrated pressure/temperature gauges
Electronic Check printed circuit boards (PCB) are free of
Inspections dust
Check there are no signs of damage/hot
spots on printed circuit boards
Check the operation status of Level Sensor.
Check EXV winding resistance ( don t disturb
unless repair required )
Check the operation status of EXV.
Check physical condition of compressor.
Performance evaluation (log & analysis)
Check IGV assembly operating correctly
Check compressor fault log
Check calibration of pressure and
temperature sensors
Compressor
Check backplane voltage test points
Check
Check DC bus voltage
Energized: 10 years
Replace DC Capacitor Assembly
De-energized: 5 years
Check operation of all system safety devices
and interlocks.
Perform moisture-prevention measures.
Replace Soft Start fan 5 Years

Check all modules and connections are
secure
Check all mounting bolts are secure
Check operation of IGV assembly
Check for refrigerant leaks
Check for mechanical damage
Compressor Refrigeration Circuit Inspections
Refrigeration Check operating temperatures and pressures
Circuit Inspections Inspection: Annually
Check Liquid Injection Piping Filter.
Replacement: 5 Years
Performance evaluation (log conditions and
analysis)
Check for insulation damage
Check chilled water sensors are secure and
installed with adequate heat transfer medium
Check water flows and pressure drops are as
Evaporator &
per design conditions
Chilled Water
Check flow switch operation
Circuit Inspection
Check for leaks
Check water strainers
Clean evaporator tubes (as required)
Performance evaluation
Check chilled water sensors are secure and
installed with adequate heat transfer medium
Check water flows and pressure drops are as
Condenser &
per design conditions
Cooling Water
Check flow switch operation
Circuit Inspection
Check for leaks
Check water strainers
Clean condenser tubes
Notes:
1. Engage in period maintenance as per requirement given in the Instruction Manual to ensure
normal operation of the chiller.
2. In case of fire, it must turn off the power switch and put out the fire with extinguisher.
3. The chiller should be installed in a location away from the source of flammable materials such
as gasoline, alcohol and oil products to avoid explosion.
4. Do not touch the discharge pipe with your hands to prevent scalding (Above 85°C).
5. Do not cool or heat drinking water and food with the chiller.
16. OPRATION MAINTENANCE GUIDANCE

16.1. OPERATION AND MAINTENANCE
CAUTION
The chiller has been adjusted to the best working condition when it leaves the factory, and
the user must not change the operating parameters at will.
16.1.1 INSPECTION OF OPERATION STATUS

When the unit runs stably, the user should pay attention to the following points:
1. Condenser level:
The liquid level of the refrigerant should be visible from the sight glass. If the liquid level is too high
or there is no liquid level, check whether the unit operation data is normal.
2. Touch screen liquid level readings:
The liquid level observed by the condenser sight glass is opposite to the liquid level reading
displayed on the touch screen. The higher the actual liquid level of the condenser, the smaller the
liquid level reading. When the unit is running stably, the liquid level reading range is about 45% to
55%.
3. Approaching temperature of the evaporator:
When the approach temperature of the evaporator is higher than 3°C, it should be viewed from the
sight glass whether there is boiling liquid in the evaporator. If it can be seen, it may be dirty blockage
of chilled water system. if not, it should be checked whether dirty blockage of filter results in
insufficient liquid supply or whether the system lacks refrigerant.
4. Approaching temperature of the condenser:
When the approaching temperature of the cooling water(temperature difference between

condensation temperature and cooling water outlet) is higher than 3°C. Continuous observation
should be made of the trend of temperature change, and if the approaching temperature tends to
increase further, check whether the cooling water quality is outside standard and clean the
condenser as needed.
5. Cooling water inlet temperature:
When the inlet cooling water temperature is higher than 33°C, please check whether the capacity
of cooling tower is too small. When the cooling water inlet temperature exceeds 35°C, the chiller will
alarm (but not stop) to warn the cooling water inlet temperature is too high.
Relationship diagram between cooling water inlet temperature and COP:
Fig. 58
CAUTION
The lower temperature of the cooling water, the higher COP of the chiller. In order to improve
the energy saving of the chiller, it is necessary to ensure that the inlet temperature of cooling
water is within a reasonable range as far as possible.
CAUTION
In order to maintain the efficient operation of the unit, it is recommended to contact Miller
local sales when the operation data or status is abnormal.
16.1.2 MAINTENANCE
1. Description of pipeline system faults:
(1) Circulating water cutoff: When there is no circulating water in the pipeline or the flow rate is too
low, the differential pressure switch on the pipeline will act, causing the control system to alarm and
the unit will stop. At this point, it is necessary to check the fault of the water circulation system, and it
can be restarted manually after the circulating water system returns to normal.
(2) The temperature of chilled water outlet is too low: When the temperature of chilled water outlet
is lower than the temperature of anti-freezing protection, the control system will alarm and the unit
will stop. The system can be restarted manually until the temperature of chilled water rises and the
fault is eliminated.
CAUTION
Freeze-proof protection, water flow protection and low-pressure protection shall not be
invalidated by any means at any time.
2. Description of compressor fault:
(1) When the compressor fails to start, it is necessary to contact Miller after-sales personnel to
troubleshoot.
(2) Compressor startup failure may be due to low suction pressure, excessive exhaust pressure,
excessive exhaust temperature, compressor communication failure, compressor interlock switch
failure, bearing failure, inverter failure, high current, and other sensor failures.
CAUTION
When the chiller alarms and stops, it should be reset by manually pressing the reset button.
3. Alarm instructions
If the unit has an alarm message but the unit does not stop, it should be checked as far as possible to
avoid potential hazards to the unit operation.
(1) Cooling-water inlet temp high: Alarm warning occurs when cooling water inlet temperature is
higher than 35°C. The cooling water system should be checked to see if the capacity of the cooling
tower is insufficient.
(2) Please clean the scaling condenser: This fault information represents the serious scaling of the
condenser. It is necessary to clean the condenser as soon as possible. Usually, when the
approaching temperature of cooling water (the difference between condensation temperature and
cooling water outlet temperature) is higher than 3°C, the trend of temperature change should be
continuously observed. If the approaching temperature is further increased, the quality of cooling
water should be checked and the condenser should be cleaned as needed.
(3) Wait for the chiller to restart, please wait: It indicates that the chiller is in a set period of
downtime interval, which is usually 5 minutes. After that, the fault prompt will automatically
eliminated.
4. System Freeze-proof During Maintenance
When charging the chiller with refrigerant, or when discharging refrigerant for the sake of servicing,
there is a possibility that the evaporator or condenser ducting will crack due to freezing. Whenever
the pressure in the enclosure is below 0.2MPa, it may lead to freezing of ducting. Hence, it is
necessary to maintain circulation of water in the system or to completely drain the water away.
CAUTION
In case of chiller shutting down due to fault, it needs to restart the chiller after identifying and
removing the fault. Never force to start the chiller without identifying the fault. Besides, In
case of abnormal vibration or noise during operation, shut down the system immediately and
find out the cause.
CAUTION
In case of refrigerant leakage or chilling water leakage, it needs to turn off all the valves. In
the event, the chiller cannot be shut down with control switch, cut off all the power supply.
16.3. ELECTRICAL MAINTENANCE

1. Electric control cabinet should be well ventilated. Operating ambient temperature should be less
than 40°C and ambient relative humidity should be less than 95%. The control box is strictly
prohibited from dripping.
WARNING
It is strictly forbidden to place tools or other sundries in the electric cabinet.
2. Do not arbitrarily adjust the electrical devices. Do not connect other electrical equipment or
wires to the electrical connection nodes.
3. The circuit breaker and AC contactor in the control cabinet should be inspected and maintained
at least once a year to check whether the switches and the contactor contacts are normal.
4. The cooling fan in the control cabinet should be maintained and cleaned at least once a year,
and pay attention to the faults during the routine inspection.
WARNING
Installation, commissioning and maintenance of equipment must be completed by
careerman. Anti-static measures should be taken in the process of operation. It is strictly
forbidden to install, debug, repair or refit the unit privately.
5. Do not shut down the unit by cutting off the main power supply in case of emergency.
WARNING
In case of chiller shutting down due to fault, it needs to restart the chiller after identifying and
removing the fault. Never force to start the chiller without identifying the fault.
6. EMERGENCY STOP is the emergency stop button. In case of emergency, it is necessary to

press this button immediately. Do not use it easily in peacetime. When the button is pressed, the
control system will be powered off and can be reset by turning the button.
WARNING
Power must be removed before any maintenance of the electrical control unit!
WARNING
Fuse of specific capacity should be used. Iron wire or copper wire cannot serve as a
substitute. Otherwise, it will cause serve accident such as a big fire.
WARNING
Never bypass protection device and directly connect wires, lest it will cause a major fault.
WARNING
Never change the setting values of protection devices lest it will lead to an unexpected result.
WARNING
During operation, never touch any electronic part except the switches. Never push the
electromagnetic button lest it will cause a major accident.
17. TROUBLESHOOTING
N/A FAULT CAUSE REMOVAL METHOD
Check the water flow
Water flow is less than the
Low water flow Check the water pump
1 minimum water flow of the
protection Check the water side filter
differential pressure switch
Check the water flow switch
Check the temp sensor wiring (Reference
circuit diagram)
Check the wiring terminal
2 Temp sensor fault Temp sensor abnormal
Check the temp sensor resistance
Check is there enough sillicane base
thermal grease in the blind pipe
Check the pressure sensor wiring
(Reference circuit diagram)
Fault of pressure The pressure sensors Check the wiring terminal
3 sensor (Condenser (Condenser and Check the sensor resistance
and Economizer) Economizer) are abnormal Check whether the sensor model is correct
Check whether the sensor is tightened and
whether the needle valve thimble is opened
Check the sensor wiring (Reference circuit
Fault of liquid level The liquid level sensor is diagram)
4
sensor abnormal Check the wiring terminal
Check the sensor resistance
Failure or blockage of EXV Repair or replace the EXV
The drying filter is blocked Replace the drying filter
IGV is not fully opened Check the degree of opening of the IGV
Insufficient refrigerant Charge refrigerant
5 Low suction pressure Fault of pressure sensor Repair or replace pressure sensor
Water flow is less than the Check the water flow according to the
minimum water flow instructions
The temperature of chilled
Check the target water temperature setting
water is too low
The evaporator outlet Check the chilled water pump and water flow
6 Anti-frozen protection temperature is lower than
Check the chilled water outlet temp sensor
the protection set point
The cooling water Excessive temperature of
7 Check the water system
inlet temp high cooling water inlet
Please clean the Check if condenser scales heavily and clean

8 Condenser scales heavily
scaling condenser it
Non-condensable gas in
Discharge non-condensable gas
the system
Excessive refrigerant char
Recycling excess refrigerants
ge
Excessive discharge Check valve is closed Open the check valve
9
pressure Check the water flow according to the
Water flow is too low
instructions
Error in setting alarm value Check high voltage setpoint and high
of high voltage voltage switch
Condenser scales heavily Clean the tubes
Check whether the temperature of chilled
High temperature of Failure of chiller start-up
water is higher than that of cooling water
chilled water or due to high temperature of
10 (When the chiller is first started or during the
insufficient cooling of chilled water or insufficient
transition season, the cooling water flow can
compressor cooling of compressor
be adjusted appropriately)
Check RS485 wiring on compressor I/O
board
Check whether the compressor and PLC
Abnormal communication
Compressor power control mode is Modbus (through SMT
11 between compressor and
off software)
PLC
Check compressor configuration and PLC
configuration
Check if the compressor is powered
1. Download compressor fault log with SMT
Compressor failed to 2. Make a video report with SMT
12 Compressor internal fault
start 3. Send the video and faulu log to Miller
serviceman to solve the problem
CAUTION
Specially-trained air-con technician should be posted to maintain normal operation of chiller.
The technician should observe from time to time, record and analyze relevant data, then
make judgment on the operation of the chiller.
MILLER TURBO POWER (USA)
Chiller Unit division
Phone: (917) 809 4700
30 Broad Street 14th Floor
New York, NY 10004, USA
Email: [email protected]
www.millerturbo.com

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Miller Water-Cooled Oil-Free Centrifugal Chiller

Installation, Operation, Maintenance Manual

Miller Air Conditioner Electric Co., Ltd

3. SYSTEM WORKING PRINCIPLE................................................................................................................... 2

4. CHILLER COMPONENTS .............................................................................................................................. 4

4.1. E.G. SINGLE-COMP. CHILLER

5. EQUIPMENT OVERVIEW ............................................................................................................................... 6

SHIPMENT AND INSTALLATION MANUAL

8. WATER CIRCUITS INSTALLATION ............................................................................................................. 26

8.1. CHILLED AND COOLING WATER CIRCUIT

9. ELECTRICAL INSTALLATION ..................................................................................................................... 30

9.6. ON-SITE WIRING

10. OPERATION REQUIREMENT.................................................................................................................... 46

10.1. WATER QUALITY STANDARD

11. SYSTEM CHECKS BEFORE STARTING UP............................................................................................. 48

11.1. CHILLER CHECKS

12. PRESTART SYSTEM CHECKLIST ............................................................................................................ 51

13. STARTING UP............................................................................................................................................. 52

13.1. STARTING UP INSTRUCTIONS

14. DEBUG REPORT........................................................................................................................................ 62

15. REGULAR MAINTENANCE ....................................................................................................................... 66

15.1. MAINTENANCE SCHEDULE

16. OPRATION MAINTENANCE GUIDANCE .................................................................................................. 68

16.1. OPERATION AND MAINTENANCE

17. TROUBLESHOOTING ................................................................................................................................ 74

Centrifugal chiller I Conventional model

3. SYSTEM WORKING PRINCIPLE

Load balancing valve

(For reference only)

Dry filter Dry filter

(For reference only)

Electronic Expansion Valve Butterfly Valve

Ball Valve One-way Valve

Angle Valve Temperature Sensor

Relief Valve Pressure Sensor

Liquid Level Sensor Filter

4.2. e.g. DOUBLE-COMP. CHILLER

COMPONENT DESCRIPTION COMPONENT DESCRIPTION

FRONT VIEW REAR VIEW

COMPONENT DESCRIPTION FUNCTION

COMPRESSOR CONTROL AND MONITORING COMPONENTS:

COMPONENT DESCRIPTION FUNCTION

COMPONENT DESCRIPTION FUNCTION

Load Balancing Pipeline

EXV for System

EXV for Economizer

REFRIGERANT FLOW CONTROL

REFRIGERANT ISOLATION VALVES

WATER FLOW SWITCHES

MILLER CONTROL SYSTEM

INTELLIGENT CLOUD SERVICE SYSTEM

CENTRALIZED CONTROL SYSTEM (User Selectable)

The unit shall meet the following requirements during transportation:

1. Check whether the documentation of the chiller is complete;

4. Check for refrigerant leakage.

5. If there is any damage or doubt, please contact Miller after-sale immediately.

when level horizontally.

7.3. INSTALLATION REQUIREMENTS

8. WATER CIRCUITS INSTALLATION